Mounting tool and mounting method for rotary coupling device

Abstract

A tool for mounting a rotary coupling device on a shaft, a rotary coupling device and a mounting tool kit and a method of mounting a rotary coupling device are provided. The coupling device includes a hub disposed about an axis of the shaft and spaced apart from the shaft. The bore in the hub is aligned with the bore in the shaft and receives a fastener extending through the hub bore and into the shaft bore. The tool comprises: a body defining an aperture having a shape complementary to the shape of the hub and defining at least one flat portion; and an arm extending from the body in a direction perpendicular to and away from the axis. At least a portion of the arm is axially spaced from the hub, allowing a tool to access the deeply recessed hub and preventing rotation of the device and the shaft when the fastener rotates.

Description

Technical Field

[0001] The present invention relates to mounting a rotary coupling device, such as a clutch or brake, onto a shaft. Specifically, the present invention relates to an installation tool for a rotary coupling device, a rotary coupling device and an installation tool kit, and a method of installing a rotary coupling device that allows the rotary coupling device and the shaft to be fixed against rotational movement as a fastener used to attach the rotary coupling device to the shaft is rotated, thereby maintaining rotational alignment of the rotary coupling device and the shaft and tightening the fastener to a desired torque. Background Art

[0002] Rotary coupling devices, such as clutches or brakes, are used to control torque transmission between two bodies. The device includes components such as a rotor coupled to one body and components such as an armature coupled to another body. The rotor and the armature are selectively engaged to transmit torque between the bodies.

[0003] In some applications, one of the bodies may include a shaft onto which the rotary coupling device is mounted, and the other of the bodies may include a pulley supported on the rotary coupling device. Some conventional rotary coupling devices include a pair of spaced-apart hubs - one of the hubs being disposed around the shaft and supporting one of the rotor and the armature, and the other of the hubs being spaced from the shaft and supporting the other of the rotor and the armature. The hub spaced from the shaft can be aligned with the shaft using a key that is disposed in aligned keyways in the shaft and the hub. The rotary coupling device can then be fixed to the shaft using a fastener that extends through a hole in the hub and into a corresponding hole in the shaft.

[0004] During the process of mounting a rotary coupling device onto a shaft, rotation of the fastener used to fix the rotary coupling device to the shaft can cause corresponding rotation of the shaft. This action may result in the fastener not being tightened to the desired torque. To prevent rotation of the shaft, the hub spaced from the shaft is shaped in such a way that it allows the hub to be gripped by a tool so that both the hub and the shaft can remain non-rotating when the fastener is rotated. However, in some conventional rotary coupling devices, the hub is relatively recessed far within a pulley or another component of the device supported on the hub. In such devices, conventional wrenches and other tools often cannot reach the hub to grip the hub and / or interfere with other tools used to rotate the fastener. Thus, installers often resort to time-consuming and / or unsafe methods to engage the hub and prevent rotation of the hub and the shaft.

[0005] The inventors have recognized herein the need for an installation tool for a rotary coupling device, a rotary coupling device and an installation tool kit, and a method of installing a rotary coupling device that will minimize and / or eliminate one or more of the above-described deficiencies. Summary of the Invention

[0006] The present invention relates to the installation of a rotary coupling device, such as a clutch or a brake, onto a shaft. Specifically, the present invention relates to an installation tool for a rotary coupling device, a rotary coupling device and an installation tool kit, and a method of installing a rotary coupling device that allows the rotary coupling device to be fixed against rotational movement when a fastener for attaching the rotary coupling device to the shaft is rotated, thereby maintaining the rotational alignment of the rotary coupling device with the shaft and fastening the fastener to a desired torque.

[0007] A tool for installing a rotary coupling device onto a shaft according to one embodiment includes: a body that defines an aperture configured to locate about an axis extending through the shaft, a hub of the rotary coupling device, and a fastener extending through the hub and into the shaft. The aperture has a shape complementary to the shape of the hub of the rotary coupling device and defines at least one flat portion. The tool further includes an arm extending from the body. The arm includes: an axially extending portion that extends from the body in a direction parallel to the axis; and a radially extending portion that extends from the axially extending portion in a direction perpendicular to and away from the axis.

[0008] A tool for installing a rotary coupling device onto a shaft according to another embodiment includes a body that defines an aperture configured to locate about an axis extending through the shaft, a hub of the rotary coupling device, and a fastener extending through the hub and into the shaft. The aperture has a shape complementary to the shape of the hub of the rotary coupling device and defines at least one flat portion. The body has a first axial end configured to receive the hub and a second axial end spaced apart from the hub. The tool further includes an arm that extends from the second axial end of the body in a direction perpendicular to and away from the axis.

[0009] A rotary coupling device and an installation tool kit according to one embodiment includes a rotary coupling device configured to be installed onto a shaft. The rotary coupling device has a hub configured to be disposed about a rotational axis of the shaft and spaced apart from the shaft. The hub has a hole configured to be centered about the rotational axis, aligned with a corresponding hole in the shaft, and receive a fastener that extends along the rotational axis and through the hole in the hub and into the hole in the shaft. The rotary coupling device and the installation tool kit further includes a tool for installing the rotary coupling device onto the shaft. The tool includes a body that defines an aperture configured to be located about the rotational axis and receive the hub of the rotary coupling device. The aperture has a shape complementary to the shape of the hub and defines at least one flat portion. The tool further includes an arm extending from the body. At least a portion of the arm is configured to be axially spaced apart from the hub and extend in a direction perpendicular to and away from the rotational axis. The tool is configured to be fixed against movement about the rotational axis when the fastener is rotated into the hub of the rotary coupling device and the shaft.

[0010] A method for installing a rotary coupling device according to one embodiment includes installing the rotary coupling device onto a shaft such that a hub of the rotary coupling device is disposed about and spaced from a rotational axis of the shaft. The hub has a hole configured to be centered about the rotational axis and aligned with a corresponding hole in the shaft. The method further includes moving a tool along the rotational axis and engaging the hub. The tool includes a body defining an aperture having a shape complementary to the shape of the hub of the rotary coupling device and defining at least one flat portion. The tool further includes an arm extending from the body in a direction perpendicular to and away from the rotational axis. At least a portion of the arm is axially spaced from the hub of the rotary coupling device. The method further includes inserting a fastener through the hole of the hub and into the hole of the shaft and rotating the fastener about the rotational axis while preventing the tool from rotating about the rotational axis, thereby preventing rotation of the hub of the rotary coupling device and the shaft.

[0011] Compared to conventional tools, kits, and methods, the installation tool, rotary coupling device, and installation tool kit for a rotary coupling device according to the teachings herein and the method for installing a rotary coupling device represent an improvement. Specifically, the tools, kits, and methods of the present invention enable an installer to prevent rotation of the hub of a rotary coupling device during rotation of a fastener used to secure the rotary coupling device to a shaft and, thus, prevent rotation of the shaft on which the rotary coupling device is installed, even in devices where the hub is deeply recessed within a pulley or another component of the device. As a result, alignment of the shaft with the rotary coupling device can be maintained and the fastener can be tightened to a desired torque without resorting to time-consuming and / or unsafe methods of engaging the hub and rotating the shaft.

[0012] The foregoing and other aspects, features, details, utilities, and advantages of the present invention will be apparent from the following description and claims and by reference to the drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0013] Figure 1 is a plan view of a rotary coupling device forming part of one embodiment of a rotary coupling device and installation tool kit according to the disclosed teachings.

[0014] Figure 2 is Figure 1 a cross-sectional view of the rotary coupling device.

[0015] Figure 3 is a perspective view of one embodiment of an installation tool for a rotary coupling device for Figures 1 - 2 the rotary coupling device.

[0016] Figure 4 is Figures 1 - 2 the rotary coupling device and Figure 3 the installation tool.

[0017] Figure 5 is a perspective view of another embodiment of an installation tool for a rotary coupling device for Figures 1 - 2 .

[0018] Figure 6 is a flowchart showing an embodiment of a method of installing a rotary coupling device. DETAILED DESCRIPTION

[0019] Referring now to the drawings, in which like reference numerals are used to identify like components in different views, Figures 1 - 2 there is shown a rotary coupling device 10 forming part of a rotary coupling device and an installation tool kit according to an embodiment of the present invention. The device 10 functions as a clutch to selectively transmit torque from an input shaft 12 to an output member 14. When torque is not transmitted to the output member 14, the device 10 also functions as a brake on the output member 14. The device 10 may be provided for use in a riding lawn mower or similar device. However, those of ordinary skill in the art will understand that the device 10 may be used in a variety of applications that require a clutch or a brake. The device 10 may include a spacer or hub 16, a rotor 18, an electromagnet including a field housing 20 and an electrically conductive assembly 22, a brake plate 24, an armature 26, and one or more permanent magnets 28.

[0020] The input shaft 12 provides a source of torque for driving the output member 14. The shaft 12 may be made of conventional metals and metal alloys and may be solid or tubular. The shaft 12 is centered on a rotational axis 30 and is driven by an engine, an electric motor, or other conventional power source. The shaft 12 defines a hole 32 in one axial end, which is configured to receive a fastener (not shown), such as a bolt that extends through the hub 16 and is used to secure the device 10 to the shaft 12. The hole 32 may include a plurality of threads configured to engage corresponding threads on the fastener. In the illustrated embodiment, the input shaft 12 is inserted into the device 10 on the side of the device 10 opposite the output member 14. However, it should be understood that the orientation of the input shaft 12 and the hub 16 may be reversed such that the input shaft 12 is inserted into the device 10 on the same side as the output member 14.

[0021] The output member 14 transmits torque to a driven device, such as a lawn mower blade. The member 14 may include a conventional pulley around which a torque transmission belt is wound and coupled to the driven device.

[0022] The hub 16 is configured to support the output member 14 in an assembled relationship with other components of the device 10 and can be made of a conventional material including powdered metal. The hub 16 is arranged about an axis 30 and can be centered on the axis 30. The hub 16 is generally annular in shape and defines a bore 34. The bore 34 is provided about the axis 30 and can be centered on the axis 30, aligned with the bore 32 in the shaft 12, and configured to receive a fastener (not shown) that extends through the bore 34 and into the bore 32 and is used to secure the clutch 10 to the input shaft 12. The axial end of the hub 16 adjacent to the input shaft 12 has a generally circular outer surface but defines a keyway configured to receive a key 36 of the rotor 18, and the key 36 extends into aligned keyways in the input shaft 12 and the hub 16. The opposite axial end of the hub 16 remote from the input shaft 12 defines a flange 38. Refer to Figure 1 , the flange 38 has a shape defining one or more flats 40 that can be gripped by a mounting tool or otherwise engaged, as described in more detail below. In the illustrated embodiment, the flange 38 defines two diametrically opposed flats 40 separated from each other by a pair of arcuate or curved edges.

[0023] Refer again to Figure 2 , the rotor 18 is provided for selectively engaging the armature 26 to transmit torque between the input shaft 12 and the output member 14. The rotor 18 is arranged about the axis 30 and is coupled to the input shaft 12 for rotation therewith. The rotor 18 can be made of conventional metals and metal alloys and includes a hub 42 and a rotor disk 44.

[0024] The hub 42 is tubular and includes a key 36 that extends radially inwardly and is configured to be received within the keyways of the input shaft 12 and the hub 16. Near each axial end, the hub 42 supports bearings 46, 48. The hub 42 defines axially extending inner rotor poles 50 at its radially outermost diameter. The hub 42 also defines axially extending recesses 52 that are radially inward of the poles 50 for purposes described below.

[0025] The disk 44 extends radially outward from the hub 42. The disk 44 is coupled to the hub 42 by a press - fit relationship, for example, including a plurality of complementary lugs and notches. As is known in the art, the disk 44 may include multiple rows of radially - spaced and angularly - spaced banana - shaped slots 54. When the conduction assembly 22 is energized, the slots 54 enable magnetic flux to travel back and forth across the air gap between the disk 44 and the armature 26, thereby enabling a high - torque engagement between the rotor 18 and the armature 26. In the illustrated embodiment, the disk 44 includes three rows of slots 54. However, it should be understood that the number of rows of slots 54, the number of slots 54 in any row, and the size and shape of the slots 54 may vary. The disk 44 defines axially - extending outer rotor poles 56 at its outer diameter. The poles 56 are radially aligned with and radially outwardly spaced from the poles 50.

[0026] The field housing 20 is arranged to accommodate the conduction assembly 22. The housing 20 also forms part of a magnetic circuit that enables selective engagement of the rotor 18 and the armature 26. The field housing 20 may be made of conventional metals and metal alloys, including steel. The housing 20 is cylindrical and is disposed about the axis 30. See Figure 1 , the housing 20 is fixed, for example, by fasteners 58 extending through slots in the housing 20 to prevent rotation. See again Figure 2 , the cross - section of the housing 20 is generally U - shaped and includes a radially - inner annular member 60 and a radially - outer annular member 62.

[0027] The inner member 60 is supported on the outer race of the bearing 46. The cross - section of the member 60 is generally L - shaped and defines an axially - extending inner pole 64. The pole 64 extends into the recess 52 of the hub 42 of the rotor 18 and is disposed radially inward of the inner rotor pole 50.

[0028] The outer member 62 is coupled to and supported on the inner member 60. The outer member 62 defines an end wall 66, an axially - extending outer pole 68, and a flange 70. The end wall 66 extends radially outward from the member 60 and defines one or more recesses 72 for purposes described below. The pole 68 is integral with the end wall 66 and extends axially from the end wall 66. The pole 68 is disposed radially outside the pole 56 of the rotor 18. An aperture 74 is also formed through the pole 68 for wires of the conduction assembly 22 to extend outwardly through the pole 68. The flange 70 is integral with the pole 68 at the end of the pole 68 opposite the end wall 66 and extends radially outward from the pole 68. Refer to Figure 1 , the flange 70 extends along at least a portion of the circumference of the pole 68.

[0029] A conductive assembly 22 is provided to create a magnetic circuit between the rotor 18, the spacer 76 (or the hub 16 if the orientation of the input shaft 12 is reversed), the field housing 20, and the armature 26 to cause the armature 26 to move into engagement with the rotor 18 and transfer torque from the input shaft 12 to the output member 14. The conductive assembly 22 is generally annular and is disposed within the field housing 20 about an axis 30. In particular, the assembly 22 is disposed between the inner pole 64 and the outer pole 68 of the housing 20. The assembly 22 includes a conductor 78 and a housing 80.

[0030] The conductor 78 may include a conventional copper coil, although other known conductors may alternatively be used. The conductor 78 may be electrically connected to a power source (not shown), such as a battery. When the conductor 78 is energized, a magnetic circuit is formed between the rotor 18, the spacer 76 (or the hub 16 if the input shaft 12 is oriented oppositely), the field housing 20, and the armature 26. Magnetic flux flows from the pole 68 of the housing 20 across an air gap to the pole 56 of the rotor 18. The flux then travels back and forth across the air gap between the disk 44 and the armature 26. The flux then flows from the disk 44 to the hub 42 of the rotor 18 and back to the members 60, 62 of the field housing 20 along various paths as indicated by the arrows in Figure 2 the figure.

[0031] The housing 80 is provided to contain the conductor 78 and also serves to mount the conductor 78 within the field housing 20. The housing 80 may be molded from a conventional plastic. The housing 80 may include an integral terminal connector 82 through which the conductor 78 may be electrically connected to the power source. The connector 82 may extend through an aperture 74 in the field housing 20. The housing 80 may also define one or more lugs 84 sized to be received within recesses 72 in the end wall 66 to prevent rotation of the conductive assembly 22. The housing 80 may also include a radially outwardly extending flange 86 disposed adjacent the outer pole 68 of the field housing 20, and the flange 86 may be attached to the field housing 20 at a plurality of points.

[0032] The brake plate 24 provides a braking surface for engagement by the armature 26 to the brake output member 14. The brake plate 24 may be made of a conventional material having a relatively low magnetic reluctance, and conventional materials with relatively low magnetic reluctance include conventional metals and metal alloys, such as steel. The brake plate 24 extends around at least a portion of the periphery of the device 10 and is coupled to the field housing 20. In particular, the brake plate 24 is coupled to the flange 70 of the field housing 20 using one or more fasteners 88. The fasteners 88 may be made of a non-magnetic material or a material having a relatively high magnetic reluctance to reduce or eliminate flux transfer between the brake plate 24 and the field housing 20, and thereby facilitate clutch engagement when the conduction assembly 22 is energized. The brake plate 24 may be axially spaced from the flange 70 of the field housing 20 using one or more spacers 90. The spacers 90 may include holes 92 through which the fasteners 88 extend. The spacers 90 may also be made of a non-magnetic material or a material having a relatively high magnetic reluctance to reduce or eliminate flux transfer between the brake plate 24 and the field housing 20. See Figure 1 , the brake plate 24 may include one or more radially extending, arcuately spaced tabs 94 that are separated by radially extending, arcuately spaced slots 96 formed in the brake plate 24 for one purpose described below.

[0033] The armature 26 is provided for transferring braking torque to the output member 14 and selectively transferring drive torque from the rotor 18 to the output member 14. The armature 26 may be made of various conventional metals and metal alloys, including steel. The armature 26 is annular in structure and is disposed about the axis 30. The armature 26 is axially spaced from the rotor 18 by an air gap. Similar to the rotor disk 44, the armature 26 includes multiple rows of radially spaced and angularly spaced slots 98 that facilitate the travel of magnetic flux back and forth between the rotor 18 and the armature 26 when the conduction assembly 22 is energized. In the illustrated embodiment, the armature 26 includes two rows of slots 98. The radially inner row of slots 98 on the armature 26 is disposed between the radially inner row and the radially center row of slots 54 on the rotor disk 44. The radially outer row of slots 98 on the armature 26 is disposed between the radially center row and the radially outer row of slots 54 on the disk 44. It should be understood that the number of rows of slots 98 on the armature 26, the number of slots 98 in any row, and the size and shape of the slots 98 may vary. The armature 26 is coupled to the output member 14. In particular, the armature 26 may be coupled to the output member 14 by a plurality of leaf springs 100. The springs 100 transfer drive and braking torque from the armature 26 to the output member 14 and allow the armature 26 to move axially relative to the member 14 and toward and away from the rotor disk 42. The springs 100 may be made of stainless steel and are connected to the armature 26 at one end and to the output member 14 at the opposite end using conventional fasteners 102, such as rivets, screws, bolts, or pins.

[0034] A magnet 28 is provided to create a magnetic path between the brake plate 24 and the armature 26, thereby pulling the armature 26 into engagement with the brake plate 24 and providing braking torque to the output member 14. The magnet 28 can include a neodymium iron boron (Nd-Fe-B) magnet or other known permanent magnet. Referring to Figure 2 , the magnet 28 can be embedded within a closed hole 104 in the brake plate 24 and can be arranged such that one face of the magnet 28 is flush with one side (and the engagement surface) of the brake plate 24. See Figure 1 , the magnets 28 can be bow-spaced from each other circumferentially around the brake plate 24. A single magnet 28 can be disposed in each tab 94, where slots 96 are used to magnetically isolate each magnet 28 from the other magnets 28. Alternatively, as long as the magnets 28 are appropriately spaced from each other, more than one magnet 28 (and / or without including slots 96) can be provided in a single tab 94. The magnets 28 can also be provided in every other tab 94 to increase the wear surface. It will also be appreciated that the number and location of the magnets 28 within the brake plate 24 can vary depending on the characteristics of the device 10 and the associated design requirements. As shown, the magnets 28 are arranged such that the opposite poles of adjacent magnets have like polarities, thereby forming a parallel magnetic path. Alternatively, the magnets 28 can be arranged such that the opposite poles of adjacent magnets 28 have opposite polarities, thereby forming a less efficient series magnetic path. Referring again to Figure 2 , the magnet 28 is axially aligned with a portion of the armature 26 and is oriented such that magnetic flux travels axially through the magnet 28.

[0035] Although a specific form of the rotary coupling device is shown in Figures 1 - 2 , it should be understood that the rotary coupling device described herein and the rotary coupling device of the installation tool kit can vary, and the installation tool described below can be used with a variety of different rotary coupling devices. For example, although the device 10 acts as both a clutch and a brake, the device can be configured to act as a clutch alone or a brake alone. Although the device 10 is actuated using electromagnetic force, the device 10 can alternatively be actuated by fluid (pneumatic or hydraulic) force. The kit described herein can include any rotary coupling device, and the installation tool described herein can be used with any rotary coupling device that is configured to be mounted on a shaft (such as the input shaft 12) and includes a hub, such as the hub 16, the hub 16 being configured to be disposed about the rotational axis 30 of the shaft 12 and spaced from the shaft 12, and the hub 16 including a hole 34, the hole 36 being configured to be centered about the rotational axis 30, aligned with a corresponding hole 32 in the shaft 12 and receiving a fastener that extends along the rotational axis 30 and passes through the hole 34 in the hub 16 and into the hole 32 in the shaft 12.

[0036] Now referring to Figure 3, which shows an embodiment of a tool 106 for mounting a rotary coupling device (such as device 10) on a shaft (such as input shaft 12). The tool 106 includes a body 108 and an arm 110.

[0037] The body 108 is configured to receive the engagement hub 16, and in particular the flange 38 of the engagement hub 16. The body 108 may be annular in shape and define an aperture 112 extending therethrough. See Figure 4 , during use, the aperture 112 is configured to be positioned about an axis 30 extending through the input shaft 12, the hub 16, and a fastener (not shown) extending through an aperture 34 in the hub 16 and into an aperture 32 in the input shaft 12. The aperture 112 has a shape complementary to the shape of the flange 38 of the hub 16 and the aperture 112. See again Figure 3 , the aperture 112 defines at least one flat portion 114. The flat portion 114 is configured to engage a corresponding flat portion 40 on the flange 38 of the hub 16. The flat portions 40, 114 cooperate to prevent relative rotation between the hub 16 and the tool 106. In the illustrated embodiment, the shape of the radially outer surface 116 of the body 108 is circular, and the aperture 112 defines a pair of diametrically opposed flat portions 114 separated by arcuate or bow-shaped segments 118. However, it should be understood that the shape of the body 108 may vary as long as the aperture 112 (which may be open or closed) has a shape complementary to the shape of the hub 16 and defines at least one flat portion 114 that is configured to engage a corresponding flat portion 40 on the hub 16 to prevent relative rotation between the hub 16 and the tool 106.

[0038] The arm 110 extends from the body 108 and is arranged to allow a user to inhibit or prevent movement of the tool 106 when a fastener extending through an aperture 34 in the hub 16 and into an aperture 32 in the input shaft 12 is rotated to secure the device 10 to the input shaft 12, and thus inhibit or prevent movement of the hub 16 of the device 10 and the input shaft 12. In the illustrated embodiment, the arm 110 includes an axially extending portion 120 and a radially extending portion 122.

[0039] The portion 120 extends from the body 108 in a direction parallel or substantially parallel to the axis 30. See again Figure 4 , the configuration of the portion 120 of the arm 110 allows the body 108 of the tool 106 to engage the hub 16 of the device 10, even in the case where the hub 16 is deeply recessed within the output member 14. See again Figure 3, portion 120 is generally rectangular in shape, and each side of portion 120 is flat. However, it should be understood that the shape of portion 120 can vary. The first axial end 124 of portion 120 is coupled to body 108, and the second axial end 126 of portion 120 is coupled to portion 122 of arm 110. The width w of portion 120 is constant, except at end 124 of portion 120, where the width of portion 120 increases as portion 120 meets body 108. Similarly, the depth d of portion 120 is constant, except at end 124 of portion 120, where the depth of portion 120 decreases as portion 120 meets body 108.

[0040] Portion 122 extends radially from portion 120 of arm 110 in a direction perpendicular or generally perpendicular to axis 30 and away from axis 30. Portion 122 is also generally rectangular in shape, and each side of portion 122 is flat. One end 128 of portion 122 is coupled to end 126 of portion 120 of arm 110. End 128 of portion 122 and end 126 of portion 120 together define an arcuate transition section 130 having an arc of ninety (90) degrees or approximately ninety degrees. Opposite end 132 of portion 122 defines a semi-circular edge and defines an aperture 134 that can be used to secure arm 110 to a fixed structure to inhibit movement of tool 106 and / or to mount tool 106 on a hook or other structure when tool 106 is not in use. In the illustrated embodiment, aperture 134 is square in shape, but it should be understood that the shape of aperture 134 can vary.

[0041] Now referring to Figure 5 , another embodiment of a tool 136 for mounting a rotational coupling device (such as device 10) on a shaft (such as input shaft 12) is shown. Tool 136 includes a body 138 and an arm 140.

[0042] The body 138 is configured to receive the engagement hub 16 and is particularly configured to engage the flange 38 of the hub 16. The body 138 may be annular in shape and defines an aperture 142 that extends through the body 138. During use, the aperture 142 is configured to locate about a fastener (not shown) that extends through the axis 30 of the input shaft 12, through the hub 16, and into the aperture 32 of the input shaft 12 through the aperture 34 of the hub 16. The aperture 142 has a shape complementary to the shape of the flange 38 of the hub 16 and the aperture 142 defines at least one flat portion 144. The flat portion 144 is configured to engage a corresponding flat portion 40 on the flange 38 of the hub 16. The flat portions 40, 144 cooperate to prevent relative rotation between the hub 16 and the tool 136. In the illustrated embodiment, the aperture 142 defines a pair of diametrically opposed flat portions 144 that are separated by arcuate or bowed segments 146. Additionally, the shape of the radially outer surface of the body 138 varies along its axial length. A portion 148 of the body 138 that defines the first axial end 150 of the body 138 is configured to engage the hub 16 during use of the tool 136 and the portion 148 has a radially outer surface that has a shape corresponding to the shape of the aperture 142. In particular, the portion 148 defines a pair of diametrically opposed flat sides 152 that are separated by diametrically opposed arcuate or bowed sides 154. Another portion 156 of the body 138 that defines the second axial end 158 of the body 138 is spaced from the hub 16 during use of the tool 136 and is circular in shape and projects further outward from the axis 30 in each radial direction relative to the portion 148 of the body 138. It should also be understood that the shape of the body 138 may vary as long as the aperture 142 (which may be open or closed) has a shape complementary to the shape of the hub 16 and defines at least one flat portion 144 that is configured to engage a corresponding flat portion 40 on the hub 16 to inhibit relative rotation between the hub 16 and the tool 136.

[0043] The arm 140 extends from the body 138 and is arranged to allow a user to inhibit or prevent movement of the tool 136, and thus inhibit or prevent movement of the hub 16 of the device 10 and the input shaft 12, when the fastener extending through the hole 34 of the hub 16 and into the hole 32 of the input shaft 12 is rotated to secure the device 10 to the input shaft 12. The arm 140 extends from the end 158 of the body 138 in a direction perpendicular to or substantially perpendicular to the axis 30 and away from the axis 30. The arm 140 is generally rectangular in shape, and each side of the arm 140 is flat. One end 160 of the arm 140 is coupled to the end 158 of the body 138. The opposite end 162 of the arm 140 defines a semi-circular edge and may define an aperture similar to the aperture 134 in the tool 106, which aperture may be used to secure the arm 140 to a fixed structure to inhibit movement of the tool 136 and / or to mount the tool 136 on a hook or other structure when the tool 136 is not in use.

[0044] Now refer to Figure 6, a method of installing a rotary coupling device 10 will be described. The method can begin with step 164 of installing the device 10 onto the input shaft 12. If replacing an existing rotary coupling device, step 164 can be preceded by steps related to removing the existing rotary coupling device and preparing (e.g., cleaning) the input shaft 12. Step 164 can include several sub-steps 166, 168. In sub-step 166, one of the device 10 and the shaft 12 is rotated about axis 30 relative to the other of the device 10 and the shaft 12 to align the key 36 on the rotor hub 42 with the keyway in the shaft 12. In sub-step 168, one of the device 10 and the shaft 12 is moved along axis 30 relative to the other of the device 10 and the shaft 12 to move the key 36 into the keyway in the shaft 12. Upon completion of sub-step 168, the hub 16 is arranged about the rotational axis 30 of the shaft 12 and spaced apart from the shaft 12, and the hole 34 in the hub 16 is centered on axis 30 and aligned with the hole 32 in the shaft 12. The method can continue with step 170: moving a tool 106 or 136 along axis 30 and engaging the hub 16. In particular, the body 108 of the tool 106 or the body 138 of the tool 136 is moved along axis 30 until the flange 38 of the hub 16 enters the orifice 112 or 142 of the corresponding tool 106, 136. Accordingly, the flat portion 114 or 144 of the respective tool 106, 136 engages the flat portion 40 on the flange 38 of the hub 16. Once the tool 106 or 136 engages the hub 16, the method can continue with step 172: inserting a fastener through the hole 34 in the hub 16 and into the hole 32 in the shaft 12. Thereafter, the method can continue with step 174: rotating the fastener about axis 30 while preventing the tools 106, 136 from rotating about axis 30 until the fastener is tightened to the desired torque. By preventing the rotation of the tool 106 or 136, rotation of the hub 16 of the device 12 about axis 30 is prevented due to the engagement of the flat portion 114 or 144 on the respective tool 106 or 136 and the flat portion 40 on the flange 38 of the hub 16. Additionally, rotation of the shaft 12 about axis 30 is prevented due to the engagement of the key 36 in the aligned keyways in the shaft 12 and the hub 16. In this way, rotation and tightening of the fastener do not cause rotation of the shaft 12, thereby preventing misalignment of the device 10 and the shaft 12 and tightening the fastener to the required torque.

[0045] Compared with conventional tools, kits, and methods, the installation tool 106 or 136 for the rotary coupling device 10, the rotary coupling device 10 and the kit of the installation tool 106 or 136, and the method for installing the rotary coupling device 10 according to the teachings herein represent an improvement. Specifically, the tools 106 or 136, the kits 10, 106 or 136, and the method of the present invention enable an installer to prevent rotation of the rotary coupling device hub 16 during rotation of a fastener for securing the rotary coupling device 10 to the shaft 12 and, thus, prevent rotation of the shaft 12 with the rotary coupling device installed thereon, even in devices where the hub 16 is deeply recessed within a pulley 14 or another component of the device 10. As a result, alignment of the shaft 12 with the rotary coupling device 10 can be maintained and the fastener can be tightened to a desired torque without resorting to time-consuming and / or unsafe methods of engaging the hub and rotating the input shaft 12.

[0046] Although the invention has been shown and described with reference to one or more specific embodiments thereof, it will be understood by those skilled in the art that various changes and modifications can be made without departing from the spirit and scope of the invention.

Claims

1. A rotary coupling device and an installation tool kit, comprising: A rotary coupling device configured to be mounted on a shaft. The rotary coupling device has a hub configured to be arranged around the rotational axis of the shaft and spaced apart from the shaft. The hub has a hole configured to be centered on the rotational axis, aligned with a corresponding hole in the shaft, and receive a fastener. The fastener extends along the rotational axis, passes through the hole in the hub, and enters the hole in the shaft; and A tool for mounting the rotary coupling device on the shaft, the tool comprising A body defining an orifice configured to be positioned around the rotational axis and receive the hub of the rotary coupling device. The orifice has a shape complementary to that of the hub and defines at least one flat portion; and An arm extending from the body, at least a portion of the arm being configured to be axially spaced apart from the hub and extending in a direction perpendicular to and away from the rotational axis; wherein the tool is configured to be fixed to prevent movement around the rotational axis when the fastener is rotated into the hub of the rotary coupling device and the shaft.

2. The rotary coupling device and installation tool kit according to claim 1, wherein The arm comprises: An axially extending portion extending from the body in a direction parallel to the rotational axis; and A radially extending portion extending from the axially extending portion in a direction perpendicular to and away from the rotational axis.

3. The rotary coupling device and installation tool kit according to claim 2, wherein The radially extending portion of the arm includes a first end connected to the axially extending portion of the arm, a second end opposite the first end, and an orifice adjacent to the second end.

4. The rotary coupling device and installation tool kit according to claim 1, wherein The body has a first axial end configured to receive the hub and a second axial end spaced apart from the hub, and the arm extends from the second axial end of the body.

5. The rotary coupling device and installation tool kit according to claim 1, wherein The body is in an annular shape.

6. The rotary coupling device and installation tool kit according to claim 1, wherein The orifice defines first and second flat portions that are radially opposed.

7. A method of installing a rotary coupling device, comprising: Mounting a rotary coupling device on a shaft such that the hub of the rotary coupling device is arranged around the rotational axis of the shaft and spaced apart from the shaft. The hub has a hole configured to be centered on the rotational axis and aligned with a corresponding hole in the shaft; Move the tool along the rotation axis and engage it with the hub. The tool includes a body and an arm. The body defines an aperture that has a shape complementary to the shape of the hub of the rotary coupling device and defines at least one flat portion. The arm extends from the body in a direction perpendicular to the rotation axis and away from the rotation axis, and at least a portion of the arm is axially spaced from the hub of the rotary coupling device; Insert a fastener through the hole in the hub and into the hole in the shaft; Rotate the fastener about the rotation axis while preventing the tool from rotating about the rotation axis, thereby preventing rotation of the hub of the rotary coupling device and the shaft.

8. The method according to claim 7, wherein, the arm of the tool includes: an axially extending portion that extends from the body in a direction parallel to the rotation axis; and, a radially extending portion that extends from the axially extending portion in a direction perpendicular to the rotation axis and away from the rotation axis.

9. The method according to claim 8, wherein, the radially extending portion of the arm includes a first end connected to the axially extending portion of the arm, a second end opposite the first end, and an aperture adjacent the second end.

10. The method according to claim 7, wherein, the body has a first axial end configured to receive the hub and a second axial end spaced from the hub, and the arm extends from the second axial end of the body.

11. The method according to claim 7, wherein, the body is in an annular shape.

12. The method according to claim 7, wherein, the aperture defines a first flat portion and a second flat portion that are radially opposite.

13. The method according to claim 7, wherein, mounting the rotary coupling device to the shaft includes: rotating one of the rotary coupling device and the shaft about the rotation axis relative to the other of the rotary coupling device to align a key in a keyway in the hub of the rotary coupling device with a keyway in the shaft; and, moving one of the rotary coupling device and the shaft along the rotation axis relative to the other of the rotary coupling device and the shaft to move the key into the keyway in the shaft.

14. A tool for mounting a rotary coupling device on a shaft, the tool comprises: a body that defines an aperture configured to locate around an axis extending through the shaft, a hub of the rotary coupling device, and a fastener extending through the hub and into the shaft. The aperture has a shape complementary to the shape of the hub of the rotary coupling device and defines at least one flat portion; and, an arm that extends from the body. The arm includes: an axially extending portion that extends from the body in a direction parallel to the axis; and, a radially extending portion that extends from the axially extending portion in a direction perpendicular to the axis and away from the axis.

15. The tool according to claim 14, wherein, the body is in an annular shape.

16. The tool according to claim 14, wherein, the orifice defines first and second flat portions that are radially opposed.

17. The tool according to claim 14, wherein, the radially extending portion of the arm includes a first end connected to the axially extending portion of the arm, a second end opposite the first end, and an orifice adjacent the second end.

18. A tool for installing a rotary coupling device on a shaft, the tool comprising: a body defining an orifice configured to position about an axis extending through the shaft, a hub of the rotary coupling device, and a fastener extending through the hub and into the shaft, the orifice having a shape complementary to the shape of the hub of the rotary coupling device and defining at least one flat portion, the body having a first axial end configured to receive the hub and a second axial end spaced from the hub; and, an arm extending from the second axial end of the body in a direction perpendicular to and away from the axis.

19. The tool according to claim 18, wherein, the body is in an annular shape.

20. The tool according to claim 18, wherein, the orifice defines first and second flat portions that are radially opposed.

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